Suspension system for autonomous transports

ABSTRACT

An autonomous transport robot for transporting a payload, the autonomous transport robot including a drive section assembly having at least one motor and a pair of drive wheels coupled to the motor, a frame configured to support a payload, a transfer arm connected to the frame and configured for the autonomous transfer of payload to and from the frame, and a suspension system movably connecting the drive section assembly and the frame allowing relative movement between the frame and the drive section assembly.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.14/576,644 filed on Dec. 19, 2014 (now U.S. Pat. No. 9,156,394) which isa continuation of U.S. patent application Ser. No. 14/245,551 filed onApr. 4, 2014 (now U.S. Pat. No. 8,919,801) which is a continuation ofU.S. patent application Ser. No. 13/326,505 filed on Dec. 15, 2011 (nowU.S. Pat. No. 8,696,010) which is a non-provisional of and claims thebenefit of U.S. Provisional Application Ser. No. 61/423,317 filed onDec. 15, 2010, the disclosures of which are incorporated by referenceherein in their entireties.

BACKGROUND

1. Field

The embodiments generally relate to storage and retrieval systems and,more particularly, to autonomous transports of the storage and retrievalsystems.

2. Brief Description of Related Developments

Warehouses for storing case units may generally comprise a series ofstorage racks that are accessible by transport devices such as, forexample, fork lifts, carts and elevators that are movable within aislesbetween or along the storage racks or by other lifting and transportingdevices. These transport devices may be automated or manually driven.Generally the surfaces over which the transport devices operate may haveuneven surfaces.

When transporting the cases to and from the storage racks with automatedtransports it would be advantageous to keep the wheels of the automatedtransports in substantial contact with the surfaces of the travel decks.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing aspects and other features of the disclosed embodimentsare explained in the following description, taken in connection with theaccompanying drawings, wherein:

FIG. 1 schematically illustrates an exemplary storage and retrievalsystem in accordance with the embodiments;

FIG. 2 illustrates a schematic plan view of an exemplary storage andretrieval system in accordance with the embodiments;

FIGS. 3A and 3B are schematic illustrations of an exemplary autonomoustransport vehicle in accordance with the embodiments;

FIG. 4 is an schematic illustration of a portion of the autonomoustransport vehicle of FIG. 3 in accordance with the embodiments;

FIG. 5 is an schematic illustration of a portion of the autonomoustransport vehicle of FIG. 3 in accordance with the embodiments;

FIGS. 5A and 5B are schematic illustrations of the autonomous transportvehicle of FIG. 3 in accordance with the embodiments;

FIGS. 6A, 6B, 6C and 6D are schematic illustrations of a portion of theautonomous transport vehicle of FIG. 3 in accordance with theembodiments; and

FIGS. 7A and 7B are schematic illustrations of a portion the exemplaryautonomous transport vehicle of FIG. 3 in accordance with theembodiments.

DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENT(S)

FIG. 1 schematically illustrates an exemplary storage and retrievalsystem in accordance with the embodiments. Although the disclosedembodiments will be described with reference to the embodiments shown inthe drawings, it should be understood that the disclosed embodiments canbe embodied in many alternate forms. In addition, any suitable size,shape or type of elements or materials could be used.

In accordance with the embodiments the storage and retrieval system 100may operate in a retail distribution center or warehouse to, forexample, fulfill orders received from retail stores for case units(where case units as used herein means items not stored in trays, ontotes or on pallets, e.g. uncontained or items stored in trays, totes oron pallets). It is noted that the case units may include cases of items(e.g. case of soup cans, boxes of cereal, etc.) or individual items thatare adapted to be taken off of or placed on a pallet. In accordance withthe embodiments, shipping cases or case units (e.g. cartons, barrels,boxes, crates, jugs, totes, pallets or any other suitable device forholding case units) may have variable sizes and may be used to holditems in shipping and may be configured so they are capable of beingpalletized for shipping. It is noted that when, for example, bundles orpallets of case units arrive at the storage and retrieval system thecontent of each pallet may be uniform (e.g. each pallet holds apredetermined number of the same item—one pallet holds soup and anotherpallet holds cereal) and as pallets leave the storage and retrievalsystem the pallets may contain any suitable number and combination ofdifferent items (e.g. each pallet may hold different types of items—apallet holds a combination of soup and cereal). In the embodiments thestorage and retrieval system described herein may be applied to anyenvironment in which case units are stored and retrieved.

The storage and retrieval system 100 may be configured for installationin, for example, existing warehouse structures or adapted to newwarehouse structures. In the embodiments, the storage and retrievalsystem may include in-feed and out-feed transfer stations 170, 160,multilevel vertical conveyors 150A, 150B, a storage structure 130, and anumber of autonomous transport vehicles or robots 110 (referred toherein as “bots”). In the embodiments the storage and retrieval systemmay also include robot or bot transfer stations (as described in, forexample, U.S. patent application Ser. No. 12/757,220, entitled “STORAGEAND RETRIEVAL SYSTEM,” the disclosure of which is incorporated byreference herein in its entirety) that may provide an indirect interfacebetween the bots 110 and the multilevel vertical conveyor 150A, 150B.The in-feed transfer stations 170 and out-feed transfer stations 160 mayoperate together with their respective multilevel vertical conveyors150A, 150B for bi-directionally transferring case units to and from oneor more levels of the storage structure 130. In the embodiments themultilevel vertical conveyors 150A, 150B may be dedicated inbound orin-feed conveyors 150A and outbound or out-feed conveyors 150B, or eachof the conveyors 150A, 150B may be used for both inbound and outboundtransfer of case units/items from the storage and retrieval system. Themultilevel vertical conveyors may be any suitable lifting devices fortransporting case units between levels of the storage and retrievalsystem. It is noted that while multilevel vertical conveyors aredescribed herein in other aspects the conveyors may be any suitableconveyors or transfer/picking devices having any suitable transport pathorientation. Some non-limiting suitable examples of a multilevelvertical conveyor can be found in, for example, U.S. patent applicationSer. No. 13/327,088 entitled “MULTILEVEL VERTICAL CONVEYOR PLATFORMGUIDES” filed on Dec. 15, 2011, U.S. patent application Ser. No.12/757,354, entitled “LIFT INTERFACE FOR STORAGE AND RETRIEVAL SYSTEMS,”(the disclosure of which is incorporated by reference herein in itsentirety) and U.S. patent application Ser. No. 12/757,220, entitled“STORAGE AND RETRIEVAL SYSTEM,” (previously incorporated by reference).For example, the multilevel vertical conveyors may have any suitablenumber of support shelves for transporting the case units to apredetermined level of the storage and retrieval system. The supportshelves may have slatted supports configured to allow fingers of thebots 110 or in-feed/out-feed transfer stations 170, 160 to pass betweenthe slats for transferring case units to and from the conveyor. Inalternate embodiments transfer of case units between the bots and themultilevel vertical conveyors may occur in any suitable manner.

As may be realized, the storage and retrieval system 100 may includemultiple in-feed and out-feed multilevel vertical conveyors 150A, 150Bthat are accessible by, for example, bots 110 on each level of thestorage and retrieval system 100 so that one or more case unit(s) can betransferred from a multilevel vertical conveyor 150A, 150B to eachstorage space on a respective level and from each storage space to anyone of the multilevel vertical conveyors 150A, 150B on a respectivelevel. The bots 110 may be configured to transfer the case units betweenthe storage spaces and the multilevel vertical conveyors with one pick(e.g. substantially directly between the storage spaces and themultilevel vertical conveyors). By way of further example, thedesignated bot 110 picks the case unit(s) from a shelf of a multilevelvertical conveyor, transports the case unit(s) to a predeterminedstorage area of the storage structure 130 and places the case unit(s) inthe predetermined storage area (and vice versa).

The bots 110 may be configured to place case units, such as the abovedescribed retail merchandise, into picking stock in the one or morelevels of the storage structure 130 and then selectively retrieveordered items for shipping the ordered items to, for example, a store orother suitable location. In one exemplary embodiment, the bots 110 mayinterface in any suitable manner with the multilevel vertical conveyors150A, 150B such as through, for example, extension of a transfer arm oreffector of the bot relative to a frame of the bot. Suitable examples ofbots are described in U.S. patent application Ser. No. 12/757,312,entitled “AUTONOMOUS TRANSPORTS FOR STORAGE AND RETRIEVAL SYSTEMS” andfiled on Apr. 9, 2010, United States Provisional Patent Applicationentitled “AUTOMATED BOT WITH TRANSFER ARM” with (Ser. No. 61/423,365)and filed on Dec. 15, 2010 (now U.S. patent application Ser. No.13/326,952 filed Dec. 15, 2011), United States Provisional PatentApplication entitled “AUTOMATED BOT TRANSFER ARM DRIVE SYSTEM” with(Ser. No. 61/423,388) and filed on Dec. 15, 2010 (now U.S. patentapplication Ser. No. 13/326,993 filed Dec. 15, 2011), United StatesProvisional Patent Application entitled “BOT HAVING HIGH SPEEDSTABILITY” with (Ser. No. 61/423,359) and filed on Dec. 15, 2010 (nowU.S. patent application Ser. No. 13/326,447 filed Dec. 15, 2011), andUnited States Provisional Patent Application entitled “BOT SENSINGPOSITION” with (Ser. No. 61/423,206) and filed on Dec. 15, 2010 (nowU.S. patent application Ser. No. 13/327,035 filed Dec. 15, 2011), thedisclosures of which are incorporated by reference herein in theirentireties.

The storage structure 130 may include multiple levels of storage rackmodules where each level includes an array of storage spaces (arrayed onthe multiple levels and in multiple rows on each level), picking aisles130A formed between the rows of storage spaces, and transfer decks 130B.In the embodiments, each level may also include respective bot transferstations for providing an indirect interface between the bots and themultilevel vertical conveyors. The picking aisles 130A and transferdecks 130B may be arranged for allowing the bots 110 to traverserespective levels of the storage structure 130 for placing case unitsinto picking stock and to retrieve the ordered case units. As may berealized, the storage and retrieval system may be configured to allowrandom accessibility to the storage spaces. For example, all storagespaces in the storage structure 130 may be treated substantially equallywhen determining which storage spaces are to be used when picking andplacing case units from/to the storage structure 130 such that anystorage space of sufficient size can be used to store items. The storagestructure 130 of the exemplary embodiments may also be arranged suchthat there is no vertical or horizontal array partitioning of thestorage structure. For example, each multilevel vertical conveyor 150A,150B is common to all storage spaces (e.g. the array of storage spaces)in the storage structure 130 such that any bot 110 can access eachstorage space and any multilevel vertical conveyor 150A, 150B canreceive case units from any storage space on any level so that themultiple levels in the array of storage spaces substantially act as asingle level (e.g. no vertical partitioning). The multilevel verticalconveyors 150A, 150B can also receive case units from any storage spaceon any level of the storage structure 130 (e.g. no horizontalpartitioning). In the embodiments the storage and retrieval system mayalso be configured so that each multilevel vertical conveyor serves apredetermined area of the array of storage spaces.

The storage structure 130 may also include charging stations 130C forreplenishing, for example, a battery pack of the bots 110. In theembodiments, the charging stations 130C may be located at, for example,transfer areas 295 (FIG. 2) of the transfer deck 130B so that the bots110 can substantially simultaneously transfer items, for example, to andfrom a multilevel vertical conveyor 150A, 150B while being charged asdescribed in United States Provisional Patent Application entitled“AUTONOMOUS TRANSPORT VEHICLE CHARGING SYSTEM” with (Ser. No.61/423,402) and filed on Dec. 15, 2010 (now U.S. patent application Ser.No. 13/326,823 filed Dec. 15, 2011), the disclosures of which areincorporated by reference herein in their entireties. The bots 110 andother suitable features of the storage and retrieval system 100 may becontrolled by, for example, one or more central system control computers(e.g. control server) 120 through, for example, any suitable network180. The network 180 may be a wired network, a wireless network or acombination of a wireless and wired network using any suitable typeand/or number of communication protocols. It is noted that, in oneexemplary embodiment, the system control server 120 may be configured tomanage and coordinate the overall operation of the storage and retrievalsystem 100 and interface with, for example, a warehouse managementsystem 125, which in turn manages the warehouse facility as a whole. Thecontrol server 120 may be substantially similar to that described in,for example, U.S. patent application Ser. No. 12/757,337, entitled“CONTROL SYSTEM FOR STORAGE AND RETRIEVAL SYSTEMS,” the disclosure ofwhich is incorporated by reference herein in its entirety.

Referring also to FIG. 2, an exemplary configuration of the storage andretrieval system 100 is shown. Other suitable exemplary configurationsof storage and retrieval systems can be found in, for example, U.S.patent application Ser. No. 12/757,381, entitled “STORAGE AND RETRIEVALSYSTEM” and filed on Apr. 9, 2010, and United States Provisional PatentApplication entitled “WAREHOUSING SCALABLE STORAGE STRUCTURE” with (Ser.No. 61/423,340) and filed on Dec. 15, 2010 (now U.S. patent applicationSer. No. 13/326,674 filed Dec. 15, 2011), the disclosures of which areincorporated by reference herein in their entireties. It should beunderstood that in the embodiments the storage and retrieval system mayhave any suitable configuration. As can be seen in FIG. 2, the storageand retrieval system 200 is configured, for exemplary purposes only, asa single-ended picking structure in which only one side of the system200 has a transfer section or deck 130B. The single-ended pickingstructure may be used in, for example, a building or other structurehaving loading docks disposed only on one side of the building. In thisexample, the storage and retrieval system 200 includes transfer deck(s)130B and picking aisles 130A that allow bots 110 to traverse an entiretyof a level of the storage structure 130 on which that bot 110 is locatedfor transporting items between any suitable storage locations/pickingaisles 130A and any suitable multilevel vertical conveyors 150A, 150B.The multilevel vertical conveyors 150A, 150B provide transport of caseunits into the storage and retrieval system 200 through inputworkstations 210 and provide output of case units from the storage andretrieval system 200 through output workstations 220. In theembodiments, the storage and retrieval system 200 includes a first andsecond storage section 230A, 230B located side by side so that thepicking aisles of each section are substantially parallel with eachother and facing the same direction (e.g. towards transfer deck 130B).However, in the embodiments the storage and retrieval system may haveany suitable number of storage sections arranged relative to each otherin any suitable configuration.

Referring to FIGS. 3A and 3B an exemplary bot 110 is shown. In theembodiments the bot 110 includes a longitudinally extended frame 110Fthat has a first end 1500 and a second end 1501 where the longitudinalaxis (e.g. Y-axis) 6000 extends from the first end 1500 to the secondend 1501. At least one drive section 110D may be coupled to one of thefirst and/or second ends 1500, 1501 in any suitable manner for drivingthe bot 110 along the transfer deck(s) 130B and picking aisles 130A(FIG. 1). The drive 110D may include drive wheels, tracks or any othersuitable drive mechanism for effecting travel of the bot along thetransfer deck(s) 130B and picking aisles 130A. The other end 1500, 1501of the bot 110 may have any suitable supports, such as caster wheels,fixed wheels, steerable wheels, and similar mechanisms for movablysupporting the bot 110 as it travels along the transfer deck(s) 130B andpicking aisles 130A. The bot 110 may have any suitable controller 1220(FIG. 1) for effecting operation of the bot 110 and/or communicationbetween the bot 110 and the control server 120 (FIG. 1). As may berealized the configuration of the bot shown in the drawings is merelyexemplary and the bot may have any suitable configuration for carryingout the detection and positioning of case units relative to the bot 110as described herein.

The frame 110F of the bot 110 may form a payload bed 1510 or othersuitable holding structure that is configured to hold case units or anyother suitable payload. The payload bed 1510 may be suitably sized foraccepting (e.g. holding) any case unit (or pickface where a pickface isone or more case units that is/are to be picked and carried by the bot110) that may be transferred into or removed from the storage andretrieval system 100. For example, in the embodiments the payload bed1510 may be larger than an expected pick size (i.e. larger than thepickface the bot is expected to pick from, for example, a storage shelfof a storage section 230A, 230B or any other suitable component of thestorage and retrieval system such as the multilevel vertical conveyors).

A fence 1510F or other suitable retaining device may be located at aside opening of the payload bed 1510. In one exemplary embodiment thefence 1510F may be attached to the frame 110F in any suitable mannersuch as with fasteners or welding. In the embodiments the fence 1510Fmay also form part of the frame 110F or be of unitary construction withthe frame 110F. The fence may include slots 1510FS disposed betweenstopping members 1510FM. The slots 1510FS may be configured to allow thefingers 1540 of the bot arm 1540A to extend through the fence 1510F in asubstantially lowered position so that the fingers 1540 can be, forexample, extended into a storage shelf below a case unit. The fence1510F may be configured to extend above the payload bed 1510 to form abarrier that substantially prevents case units from exiting the payloadbed 1510 once the case units are positioned on the payload bed 1510. Inthis example, the number of slots 1510FS is equal to the number offingers 1540 but in alternate embodiments, the fence 1510F may beconfigured such that more than one finger 1540 passes through a singleslot (e.g. the number of slots is less than the number of fingers). Itshould be noted that the fence may have any suitable configuration forpreventing case units from exiting the payload area when the case unitsare carried by the bot 110. For example, the fence may be movable sothat the stopping members are retractable such that when in an extendedconfiguration the fence prevents the case units from exiting the payloadarea.

The payload bed 1510 may include any suitable payload supports forsupporting the case units when the case units are carried by the bot110. For exemplary purposes only, the payload supports may includerollers 1510R, where a rotational axis of each roller 1510R is disposedsubstantially transversely (or laterally) to the longitudinal axis 6000of the bot 110. It is noted that the payload supports may also be belts,ball bearings or any other suitable supports. The rollers 1510R (orother suitable payload supports) may be inter-disposed with fingers 1540of the bot 110 in an alternating manner. In the embodiments the rollers1510R and the fingers 1540 may be arranged relative to each other in anysuitable manner. In one example, the payload supports may be driven inany suitable manner for justifying the payload in the payload area asdescribed in, for example, United States Provisional Patent Applicationentitled “BOT PAYLOAD ALIGNMENT AND SENSING” with (Ser. No. 61/423,220)and filed on Dec. 15, 2010 (now U.S. patent application Ser. No.13/327,040 filed on Dec. 15, 2011), the disclosures of which areincorporated by reference herein in their entireties.

The fingers 1540 of the bot arm 1540A extend laterally in the directionof arrow 1550 relative to the longitudinal axis 6000 of the bot. Thefingers 1540 are also capable of movement in the direction of arrow 1673(e.g. in a direction substantially perpendicular to the direction 1550of extension and retraction of the fingers). The fingers may be drivenby any suitable drive for lifting the pickfaces over the fence 1510F andinto/out of the payload bed 1510 of the bot 110.

A case unit contact member 1530 may be movably located at leastpartially within the payload area. The case unit contact member 1530 maybe driven laterally in the direction of arrow 1550 by any suitabledrive. In this exemplary embodiment both of the case unit contact member1530 and the fingers 1540 are configured to move laterally in thedirection of arrow 1550. The case unit contact member 1530 may beconfigured to move along rails 1530R (FIGS. 7A and 7B). The rails may bemounted to the frame 110F in any suitable manner for guiding themovement of at least the case unit contact member 1530. In theembodiments the movement of the case unit contact member 1530 may beguided in any suitable manner. For exemplary purposes only, referring toFIGS. 7A and 7B, the case unit contact member 1530 may have slidemembers 1530D for movably coupling the case unit contact member 1530 tothe rails 1530R. In the embodiments the case unit contact member 1530may be movable independent of the fingers 1540 in the direction of arrow1550 for engaging case units disposed on the payload bed 1510. Thefingers 1540 may be releasably coupled to the case unit contact member1530 in any suitable manner such that the fingers 1540 are extendedusing the case unit contact member drive system. Suitable examples ofthe bot transfer arm, fingers and transfer arm drive system can be foundin United States Provisional Patent Application entitled “AUTOMATED BOTTRANSFER ARM DRIVE SYSTEM,” having (Ser. No. 61/423,388) and filed onDec. 15, 2010 (now U.S. patent application Ser. No. 13/326,993 filedDec. 15, 2011) and United States Provisional Patent Application entitled“AUTOMATED BOT WITH TRANSFER ARM” with (Ser. No. 61/423,365) and filedon Dec. 15, 2010 (now U.S. patent application Ser. No. 13/326,952 filedDec. 15, 2011), previously incorporated by reference.

Still referring to FIGS. 3A and 3B and also to FIGS. 4, 5, 5A and 5B,the at least one drive section 110D may be connected to the frame in anysuitable manner. In one aspect the drive section 110D may be connectedto the frame by any suitable movable coupling system. In the embodimentsthe movable coupling system may be a suspension system that maypivotally (or otherwise movably) couple the drive section 110D to theframe 110F in any suitable manner to allow for relative rotation betweenthe at least one drive section 110D and the frame 110F. It should benoted that while a pivotal coupling is shown and described that in otheraspects the coupling may be, for exemplary purposes only, any suitablearticulated coupling including but not limited to linearly movablecouplings, rotatable couplings or a combination thereof. As may berealized, the bot may be supported at four points (e.g. one wheel 1261,1262, 1211, 1212 being located at substantially each corner of the bot).If all four support wheels were rigidly connected to the frame 110F andthe bot were to travel over bumps or other raised/uneven structures on,for example, the travel surface of the transfer decks 130B and/orpicking aisles 130A one or more wheels of the bot may be lifted off ofthe travel surface causing, for example, a loss of wheel traction. Asmay also be realized, a position of the bot within the storage andretrieval system 100 may be determined at least in part with anysuitable wheel odometry system, as described in e.g. U.S. patentapplication Ser. No. 13/327,035 filed on Dec. 15, 2011 entitled “BOTPOSITION SENSING” the disclosure of which was previously incorporatedherein by reference, such that a loss of wheel traction may cause anincorrect odometry reading. The movable connection between the at leastone drive section 110D and the frame 110F may substantially prevent thedrive wheels 1211, 1212 from lifting off of the travel surface such thataccurate bot positioning can be determined.

In the embodiments, the frame 110F may include a pivot or articulationmember 400. The pivot member 400 may be located substantially in linewith the longitudinal axis 6000 of the bot 110 such that the weight ofthe bot (and any payload thereon) may be centrally supported at the end1501 of the bot 110. It is noted that the pivot member 400 may besuitably located at any location on the end 1501 of the bot frame 110F.The pivot member may be integrally formed with the frame 110F or affixedto the frame in any suitable manner. In this example the pivot member400 may include any suitable recess or aperture 400R configured toaccept a corresponding pivot axle 500 of the at least one drive section110D.

The at least one drive section 110D may include a pivot axle 500configured to be received within the recess 400R of the pivot member 400or the frame 110F may include the pivot axle and the drive section 110Dmay include the pivot member. As may be realized, in the embodiments theframe and drive section may have any suitable structure for allowing thedrive section to pivot relative to the frame. In this example, the pivotaxle 500 may be pivotally retained within the pivot member 400 in anysuitable manner such as by clips, bolts, snaps or any other suitableretention devices. The pivot axle 500 and pivot member 400 may beconfigured such that the drive section 110D pivots axially in thedirection of arrow 550 with respect to the longitudinal axis 6000 of theframe 100F. The connection between the drive section 110D and the frame110F may also be configured to allow drive section 110D and the frame110F to pivot relative to each other in any suitable direction(s).

In the embodiments the drive section 110D may include one or more guidemembers 530. The guide members 530 may be wheels, sliders or any othersuitable structure that, for example, engages a surface 535 of the frame110F when the drive section 110D and the frame 110F are coupled to eachother through the pivotal coupling 510 (e.g. formed by pivot axle 500and pivot member 400). The frame 110F may also include the guide members530 such that the guide members engage a surface of the drive section110D when the frame 110F and drive section 110D are movably coupled toeach other. In this example the guide members 530 may be mounted to thedrive section 110D so that the guide members 530 allow the relativepivotal (or otherwise) movement between the drive section 110D and theframe 110F while in part substantially maintaining a substantially rigidlongitudinal axis of the bot 110. For example, in the embodiments theguide members 530 are laterally spaced (e.g. along the X-axis) from thepivot axis 510P of the pivotal coupling 510 by any suitable distance X1,X2. The distance X1, X2 between the pivot axis 510P and the guidemembers 530 may substantially prevent (through contact between the guidemembers 530 and the surface 535 of the frame) yawing motion (e.g. in thedirection of arrow 598 in the X-Y plane) between the drive section 110Dand the frame 110F. At least one of the guide members 530 may also bevertically spaced (e.g. along the Z-axis) from the pivot axis 510P byany suitable distance Z1, Z2. The distance Z1, Z2 between the pivot axis510P and the at least one of the guide members 530 may substantiallyprevent (through contact between the one of the guide members 530 andthe surface 535 of the frame) pitching motion (e.g. in the direction ofarrow 599 in the Y-Z plane) between the drive section 110D and the frame110F. In this example, the guide members 530A-530D may be locatedsubstantially at corners of an interface surface 110DS of the drivesection 110D such that two guide members 530A, 530B are verticallyspaced above the pivot axis 510P by a distance Z1 and two guide members530C, 530D are vertically spaced below the pivot axis 510P by distanceZ2. Alternatively, it is noted that all of the guide members 530A-530Dmay be located above the pivot axis or below the pivot axis. The guidemembers 530A, 530D may be laterally spaced from the pivot axis (on afirst side of the pivot axis) by distance X1 and guide members 530B,530C may be laterally spaced from the pivot axis (on a second oppositeside of the pivot axis) by distance X2. In the embodiments there may beany suitable number of guide members arranged (e.g. spaced from thepivot axis) to prevent yawing and pitching motion between the drivesection 110D and the frame 110F.

In the embodiments the axial stability (e.g. in yaw and pitch) of thecoupled drive section 110 and frame 110F may be provided through one ormore of the guide members 530A-530D and the connection between the pivotmember 400 and pivot axle 500. For example, in one exemplary embodimentthe pivot axle 500 may be axially secured within the pivot member 400 sothat the guide members 530A-530D are held substantially against thesurface 535 of the frame. One or more of the guide wheels 530, the pivotaxle 500 and pivot member 400 may also be adjustable in the longitudinalor X-direction to take up or substantially eliminate any relativemovement in the X-Y and Y-Z (e.g. yaw and pitch) planes between thedrive section 110D and the frame 110F. It is noted that the guide wheelsmay be held against the surface 535 of the frame 110 in any suitablemanner for providing a substantially rigid longitudinal coupling betweenthe drive section 110D and the frame 110F. As may be realized, the guidemembers 530 and/or the pivotal coupling 510 may only allow relativerotation (e.g. roll) between the drive section 110D and the frame 110Fin the direction of arrow 550 in the X-Z plane. In other aspects thecoupling between the drive section and frame may allow any suitablerelative movement between drive section and the frame.

As may be realized the rotation or pivoting between the drive section110D and the frame 110F in the direction of arrow 550 (in the X-Z plane)may be limited in any suitable manner. Referring to FIGS. 5, 7A and 7Bin one exemplary embodiment, protruding members 560, 561 may extend frominterface surface 110DS of the drive section 110D. In this example, theprotruding members 560, 561 are located at opposite lateral ends of thedrive section 110D but the protruding members may be located at anysuitable position for limiting pivotal travel between the drive section110D and the frame 110F. The protruding members 560, 561 may be anysuitable members configured to engage, for example, a recess or groove560G such as, for example, pins, bushings, threaded rods, studs, etc. Itis noted that while the protruding members 560, 561 are described withrespect to protruding member 560 the protruding member 561 issubstantially similar to protruding member 560. In this example theprotruding member 560 may be a stud or pin. A suitable bushing 560B maybe connected to the protruding member 560. In one example, theprotruding member 560 and the bushing 560B may be integrally formed witheach other. In another example, the bushing 560B may be fixed to theprotruding member 560 by mechanical or chemical fasteners, by aninterference fit between the two or in any other suitable manner. In theembodiments the bushing 560B may be configured to substantially cushionthe pivoting travel of the drive section 110D as the drive section 110Dreaches its travel limits. Alternatively the bushing may provide asubstantially hard stop for the pivoting drive section 110D. The travellimits of the drive section 110D may be effected by recesses or grooves560G formed in the frame 110F that correspond to each of the protrudingmembers 560, 561. The bushing 560B for each of the protruding members560, 561 and the corresponding grooves 560B may be configured such thatwhen the bot 110 is on a substantially level surface the bushing 560B isspaced from an end of the corresponding groove 560B by any suitablepredetermined distance N. The bushings 560B and grooves 560G may besized such that the bushing moves substantially in the direction ofarrow 710 within the groove 560G during pivoting movement of the drivesection 110D substantially without interference. Contact between thebushing 560B and the end of the groove 560G limits the travel (e.g.pivotal movement) between the drive section 110D and the frame 110F.

Referring to FIGS. 3B, 6A, 6B, 6C, 6D, 7A and 7B the relative pivotalmovement between the drive section 110D and the frame 110F may allowmovement between the frame 110F and the drive section 110D as the botarm 1540A (FIG. 3A) is extended laterally to pick/place a pickface fromone of the storage shelves of the storage sections 230A, 230B ormultilevel vertical conveyors 150A, 150B. The bot 110 may include alocking system or lockout mechanism having one or more locking devices600 configured to passively lock out the bot suspension forsubstantially preventing relative movement between the drive section110D and frame 110F as the bot arm 1540A is extended laterally or in anyother suitable direction (e.g. extension of the bot arm 1540A passivelycauses a locking of the suspension). Though the embodiments aredescribed with respect to the passive locking of the suspension when thearm is extended, in other aspects the locking devices 600 may beconfigured to actively lock the suspension in any suitable mannerindependent of the arm position. The locking device 600 may be locatedany suitable predetermined distance from the pivot axis 510P. In oneexample one or more locking devices 600 may be located substantially ator adjacent a respective side edge 110E1, 110E2 of the frame 110F. Whilea locking device 600 is shown adjacent each of the edges 110E1, 110E2, asingle locking device may be located along only one of the edges 110A1,110E2. Still any suitable number of locking devices 600 may be locatedat any suitable location(s) relative to, for example, the pivot axis510P.

In this example, the locking device 600 may include a body 601, aresilient member 602 and a lever member 603. The body may have anysuitable configuration and is shown in the Figs. as having asubstantially rectangular shape for exemplary purposes only. In thisexample the body may be configured for attachment to the frame 110F but,the body may also be configured for attachment to the drive section110D. The body 601 may include a recess 602R suitably sized so that theresilient member 602 may be inserted into the recess 602R. In thisexample, the resilient member 602 may be an extension spring but inalternate embodiments the resilient member 602 may be any suitableresilient member such as a leaf spring, compression spring or torsionspring and the body 601 may be suitably configured for interfacing withor housing the resilient member in any suitable manner. The lever member603 may be pivotally mounted to the body 601 in any suitable manner suchas through, for exemplary purposes only, a pivot pin 610. The levermember 603 may have a compound surface having a first surface 603A and asecond surface 603B that engages a cam 751 as described below and asurface 603E that engages an engagement member 750 as will also bedescribed below. The body 601 may be configured so that the lever member603 pivots in the direction of arrow 620 which may be substantiallyparallel with the interface surfaces 535, 110DS of the frame 110F anddrive section 110D when the body is mounted to, for example, the frame110F. The resilient member 602 may be positioned relative to the levermember 603 and/or the lever member 602 may be configured such that theresilient member 602 engages the lever member 603 for rotating the levermember 603 in the direction of arrow 798 towards an aperture 611 formedin the body 601 so that the locking device 600 is biased in a suspensionlocked position (e.g. in the direction of arrow 798) when the arm isextended and retraction of the arm acts against the force provided bythe resilient member 602 for locking the suspension so that the armmoves in the direction of arrow 799.

The locking system may also include an engagement member 750corresponding to each of the locking devices 600. The engagement member750 may be configured for attachment to, for example, the drive section110D such that the engagement member 750 extends from the interfacesurface 110DS. The engagement member 750 may be positioned so that itextends through the aperture 611 in the body for interfacing with thesurface 603E of the lever member 603. The engagement member 750 and/orthe aperture 611 may be configured to allow movement of the engagementmember 750 within the aperture 611 as the drive section 110D and frame110F pivot relative to one another.

One or more cams or idlers 751 may be rotatably mounted to the frame110F. Each cam 751 may be positioned at any suitable location of theframe 110F for interfacing with, for example, surfaces 603A, 603B (orany other suitable surface) of a respective one of the lever members 603of the one or more locking devices 600. For example, the cam 751 maymove with, for example, a respective one of the slide members 1530D asthe bot arm 1540A is extended and retracted. As the bot arm 1540A isextended the cam 751 moves in the direction of arrow 798 moving fromsurface 603B to surface 603A and eventually off of the lever 603allowing the lever member to pivot in the direction of arrow 798 towardsthe aperture 611 for locking the suspension of the bot 110. As may berealized the force exerted on the lever member 603 by the resilientmember 602 may hold the lever member against the surface of the cam 751so that as the cam 751 moves the lever member is moved towards and awayfrom the aperture 611 for locking and releasing the suspension of thebot 110. When the bot arm 1540A is retracted the cam 751 moves in thedirection of arrow 799 so that the cam 751 engages the surface 603A andthen the surface 603B of the lever 603 causing the lever to pivot in thedirection of arrow 799 for releasing the suspension of the bot 110. Asseen best in FIG. 6D, when the cam 751 is engaged with the surface 603Bof the lever, the surface 603B of the lever member 603 is oriented insuch a way so that the cam 751 remains substantially in placesubstantially without any outside influence (such as from motors orclips) due to, for example, the normal force between the cam 751 and thesurface 603B provided by the resilient member 602, which is overcomewhen the bot arm is extended. In alternate embodiments, the cam 751 maybe stationary (e.g. does not move with, for example, the slide members1530D) and driven by any suitable drive system such that the drivenrotation of the cam causes the pivoting movement of the lever 603 forlocking and unlocking the bot suspension.

As described above, the engagement member 750 extends through theaperture for interfacing with the lever member 603. As movement of thecam 751 in the direction of arrow 798 allows movement of the levermember 603 in the direction of arrow 798, the surface 603E of the levermember 603 contacts the engagement member 750 and pinches or clamps theengagement member 750 against any suitable surface of the body 601. Forexample, the engagement member 750 may extend into a block member 601Bof the body 601 such that at least a portion of the engagement member750 is located between a surface of the block member 601B and the levermember 603 (e.g. the engagement member is pinched or clamped between thelever member and the surface of the block as the cam is rotated). Thepinching or clamping force exerted on the engagement member 750 may be apredetermined force sufficient to substantially rigidly hold the drivesection 110D in a predetermined position relative to the frame 110F(e.g. substantially prevent relative pivoting between the frame anddrive section such that the drive section and frame form a singlesubstantially stiff structure) as the bot arm 1540A is laterallyextended to, for example, transfer pickfaces between the bot 110 and astorage shelf or multilevel vertical conveyor.

In the embodiments, the one or more cams 751 may be suitably connectedto any suitable bot arm drive system 770 for passively locking thesuspension of the bot 110. For example, the connection between the oneor more cams 751 and the bot arm drive system 770 may cause operation ofthe locking device 600 as the bot arm 1540A is extended forpassively/automatically locking the suspension of the bot. The cam 751may also be driven by an independently operable drive system so that thebot suspension can be actively locked/unlocked independent of the botarm position. In the embodiments, when the bot arm 1540A is in apredetermined retracted or homed position the locking device 600 isautomatically released and the drive section 110D and frame 110F areallowed to pivot (or otherwise move) relative to one another. Forexample, during operation of the bot 110, the bot 110 may traverse thepicking aisles 130A and transfer deck 130B with the bot arm 1540A in ahomed (e.g. retracted) position. With the bot arm 1540A in the homedposition the bot suspension is unlocked and the drive section 110D andframe 110F are free to pivot relative to one another allowing thesuspension to conform to the travel surfaces of the picking aisles 130Aand transfer deck 130B. As the bot arm 1540A is extended the cam 751 ispassively moved (by virtue of its connection to the bot arm drive system770) for allowing the lever member 603 to move in the direction of arrow798 for pinching or clamping the engagement member 750 and passivelylocking the bot suspension so that the drive section 110D and frame 110Fform a single substantially rigid or stiff structure substantiallyeliminating any rotation or tipping of the frame 110F that may cause theextended arm 1540A to tip relative to a surface on which a pickface islocated or being transferred to. As the bot arm 1540 is retracted to thehome position the cam 751 is passively moved for moving the lever member603 in the direction of arrow 799 for releasing the engagement member750 and passively unlocking the bot suspension. It is noted that the cammay be passively or actively driven in any suitable manner for causingoperation of the locking device.

In a first exemplary embodiment an autonomous transport robot fortransporting a payload is provided. The autonomous transport robotincludes a drive section assembly having at least one motor and a pairof drive wheels coupled to the motor, a frame configured to support apayload, a transfer arm connected to the frame and configured for anautonomous transfer of payload to and from the frame, and a suspensionsystem movably connecting the drive section assembly and the frameallowing relative movement between the frame and the drive sectionassembly.

In accordance with the first exemplary embodiment, the suspensionlockout device is configured such that the suspension is free to movewhen the transfer arm is in a retracted position.

In accordance with the first exemplary embodiment, the suspension isconfigured to maintain drive wheels of the drive section in substantialcontact with a travel surface on which the autonomous transport vehicleis travelling.

In accordance with a first aspect of the first exemplary embodiment thesuspension system includes a pivot member mounted to one of the frameand drive section and a pivot axle mounted to the other one of the frameand drive section, where the pivot axle and pivot member are configuredto engage each other to form a pivot coupling between the frame anddrive section.

In accordance with the first aspect of the first exemplary embodimentone or more guide members are connected to one of the frame and drivesection, the guide members being configured to engage an interfacesurface of the other one of the frame and drive section and at least inpart to substantially prevent relative yaw and pitch between the frameand drive section.

In accordance with a second aspect of the first exemplary embodiment theautonomous transport robot further includes a suspension lockout deviceconnected to one or more of the frame and drive section. The suspensionlockout device being configured to passively lock the suspension systemas the transfer arm is extended from the frame where locking of thesuspension system substantially prevents relative pivoting movementbetween the drive section and the frame.

In accordance with the second aspect of the first exemplary embodimentthe lockout device includes an engagement member mounted to one of theframe and drive section, a locking device mounted to the other one ofthe frame and drive section and an actuation member configured toactuate the locking device causing the locking device to engage theengagement member.

In accordance with the second aspect of the first exemplary embodimentthe lockout device includes a body and a lever member pivotally mountedto the body, wherein the engagement member extends between the body andlever member and the body and lever member are configured such thatactuation of the locking device causes the engagement member to beclamped between the lever member and body.

In accordance with the second aspect of the first exemplary embodimentthe lockout device includes a resilient member configured to move thelever member away from the engagement member for at least in partunlocking the suspension.

In accordance with the second aspect of the first exemplary embodimentthe actuation member comprises a cam connected to a drive system of thetransfer arm, wherein the cam is configured to be passively rotatedduring extension of the transfer arm.

In accordance with a second exemplary embodiment a suspension lockoutsystem for an autonomous transport vehicle is provided. The suspensionlockout system includes an engagement member mounted to one of a frameand drive section assembly of the autonomous transport vehicle, wherethe frame is configured to support a payload and the drive sectionassembly includes at least one motor and a pair of drive wheels coupledto the motor, and a locking device mounted to another one of the frameand drive section assembly of the autonomous transport vehicle, whereina suspension system of the autonomous transport vehicle connecting theframe to the drive section assembly is configured to allow pivotalmovement between the frame and drive section assembly and the suspensionlockout system is configured to release the suspension system forunrestricted movement between the frame and drive section assembly whenthe transfer arm is in a retracted position and to be automaticallylocked when the transfer arm is extended from the retracted position,and wherein locking of the suspension lockout system substantiallyprevents pivotal movement between the frame and drive section.

In accordance with a first aspect of the second exemplary embodiment thesuspension lockout system the locking device includes a body and a levermember pivotally mounted to the body, wherein the engagement memberextends between the body and lever member and the body and lever memberare configured such that actuation of the locking device causes theengagement member to be clamped between the lever member and body.

In accordance with the first aspect of the second exemplary embodimentthe suspension lockout system further includes a cam connected to thetransport arm drive system, wherein the cam is configured to bepassively rotated during extension of the transfer arm and to engage thelever member for causing clamping of the engagement member.

In accordance with the second exemplary embodiment the locking deviceincludes a resilient member configured to move the lever member awayfrom the engagement member for at least in part unlocking thesuspension.

In accordance with a third exemplary embodiment a suspension system foran autonomous transport vehicle is provided. The suspension systemincludes an articulated coupling configured to allow rolling movementbetween a frame and a drive section assembly of the autonomous transportvehicle along a common longitudinal axis where the frame is configuredto support a payload and the drive section assembly includes at leastone motor and a pair of drive wheels coupled to the motor, and asuspension locking system configured to automatically substantiallyprevent the rolling movement when an extendable transfer arm is movedfrom a retracted position, where the extendable transfer arm isconfigured to move between the retracted position and an extendedposition relative to the frame.

In accordance with the third exemplary embodiment the suspension lockingsystem is configured to automatically release the articulated couplingto allow the rolling movement when the arm is moved to the retractedposition.

In accordance with the third exemplary embodiment the suspension systemis configured to maintain drive wheels of the drive section assembly insubstantially continuous contact with a travel surface on which theautonomous transport vehicle is travelling.

In accordance with the third exemplary embodiment the suspension systemfurther includes one or more guide members mounted to one of the frameand drive section assembly at an interface between the frame and guidesection, the one or more guide members being configured to substantiallyprevent yaw and pitch motion between the frame and drive section.

In accordance with a first aspect of the third exemplary embodiment thesuspension locking system includes an engagement member mounted to oneof the frame and drive section assembly, a body mounted to another oneof the frame and drive section and a lever member pivotally mounted tothe body, wherein the engagement member extends between the body andlever member and the body and lever member are configured such thatactuation of the suspension locking system causes the engagement memberto be clamped between the lever member and body.

In accordance with the first aspect of the third exemplary embodimentthe suspension locking system includes a resilient member configured tomove the lever member away from the engagement member for at least inpart unlocking the articulated coupling.

In accordance with the first aspect of the third exemplary embodimentthe suspension locking system further includes a cam configured toengage the lever member for actuating the suspension locking system,wherein the cam is passively connected to a drive system of theextendable transfer arm.

It should be understood that the exemplary embodiments disclosed hereincan be used individually or in any suitable combination thereof. Itshould also be understood that the foregoing description is onlyillustrative of the embodiments. Various alternatives and modificationscan be devised by those skilled in the art without departing from theembodiments. Accordingly, the present embodiments are intended toembrace all such alternatives, modifications and variances that fallwithin the scope of the appended claims.

What is claimed is:
 1. A method for transporting a payload within anautomated storage and retrieval system with an autonomous transportvehicle, the method comprising: providing the autonomous transportvehicle with a drive section assembly having at least one motor and apair of drive wheels coupled to the at least one motor, and a frameconfigured with a payload support section to support the payload;justifying, with respect to the frame, the payload with a payloadjustification system having at least one degree of freedom payloadpositioning; and providing a suspension system movably connecting thedrive section assembly to the frame allowing relative movement betweenthe frame and the drive section assembly.
 2. The method of claim 1,further comprising maintaining, with the suspension system, substantialcontact between the drive wheels and a travel surface on which theautonomous transport vehicle is traveling.
 3. The method of claim 1,further comprising: providing a suspension lockout device connected toone or more of the frame and drive section assembly; and passivelylocking the suspension system with the suspension lockout device as thepayload justification system is extended from the frame, where lockingof the suspension system substantially prevents relative pivotingmovement between the drive section assembly and the frame.
 4. The methodof claim 3, wherein the suspension lockout device allows the suspensionsystem freedom of movement when the payload justification system is in aretracted position.
 5. The method of claim 3, further comprising:providing the suspension lockout device with an engagement membermounted to one of the frame and drive section assembly; providing alocking device mounted to the other one of the frame and the drivesection assembly; and actuating, with an actuation member, the lockingdevice causing the locking device to engage the engagement member. 6.The method of claim 1, where the suspension system is allowing rollingmovement between the payload support section and the drive sectionassembly along a common longitudinal axis and is automaticallysubstantially preventing the rolling movement when the payloadjustification system is moved from a retracted position, where thepayload justification system is configured to move between the retractedposition and an extended position relative to the payload supportsection.
 7. A method for transporting a payload within an automatedstorage and retrieval system with an autonomous transport vehicle, themethod comprising: providing the autonomous vehicle with a frame havingat least four corners and at least four support wheels, the four supportwheels being distributed at least proximate the at least four corners ofthe frame to support the frame on and contacting a travel surface onwhich the autonomous transport vehicle travels, where the frame definesa payload support section, and a drive section coupled to the frame by alocking articulated coupling system having an articulated couplinglockout device; and justifying a payload, within the payload supportsection of the frame, with a payload justification system having atleast one degree of freedom payload positioning; wherein the drivesection has a motor and at least two support wheels of the at least foursupport wheels are disposed on opposite sides of the drive section, theat least two support wheels being drive wheels coupled to the motor. 8.The method of claim 7, further comprising steering the autonomoustransport vehicle with at least one of the four support wheels on thetravel surface.
 9. The method of claim 7, further comprising: allowing,with the locking articulated coupling system, rolling movement betweenthe payload support section and the drive section along a commonlongitudinal axis; and automatically substantially preventing therolling movement, with the articulated coupling lockout device, when thepayload justification system is moved from a retracted position, wherethe payload justification system is configured to move between theretracted position and an extended position relative to the payloadsupport section.
 10. The method of claim 9, further comprisingautomatically releasing, with the articulated coupling lockout device,the locking articulated coupling system to allow the rolling movementwhen the payload justification system is moved to the retractedposition.
 11. The method of claim 7, wherein the articulated couplinglockout device is connected to one or more of the payload supportsection and the drive section, the method further comprising passivelylocking the locking articulated coupling system as the payloadjustification system is extended from the payload support section. 12.The method of claim 7, further comprising: providing the articulatedcoupling lockout device with an engagement member mounted to one of thepayload support section and the drive section; providing a lockingdevice mounted to the other one of the payload support section and thedrive section; and actuating, with an actuation member, the lockingdevice causing the locking device to engage the engagement member. 13.The method of claim 7, wherein the locking articulated coupling systemis allowing the drive wheels of the drive section to maintainsubstantial contact with the travel surface.
 14. The method of claim 7,further comprising: providing the locking articulated coupling systemwith a pivot member mounted to one of the payload support section andthe drive section; and providing a pivot axle mounted to the other oneof the payload support section and the drive section; where the pivotaxle and pivot member engage each other to form a pivot coupling betweenthe payload support section and the drive section.
 15. An automatedstorage and retrieval system comprising: a storage array with storagelocations arranged along a transport surface; and an autonomoustransport vehicle for transporting, on the transport surface, a payloadbetween the storage locations of the storage array, the autonomoustransport vehicle comprising a frame having at least four corners and atleast four support wheels, the four support wheels being distributed atleast proximate the at least four corners of the frame, to support theframe on and to contact the transport surface on which the autonomoustransport vehicle travels, where at least one of the four support wheelsis a steerable wheel and the frame defines a payload support section; adrive section; a payload justification system configured for at leastone degree of freedom payload positioning within the frame; and asuspension system movably connecting the drive section and the frameallowing relative movement between the frame and the drive section. 16.The automated storage and retrieval system of claim 15, wherein thesuspension system of the autonomous transport vehicle includes a lockingarticulated coupling system having an articulated coupling lockoutdevice.
 17. The automated storage and retrieval system of claim 15,wherein the drive section of the autonomous transport vehicle has amotor and at least two support wheels of the at least four supportwheels are disposed on opposite sides of the drive section, the at leasttwo support wheels being drive wheels coupled to the motor.
 18. Theautomated storage and retrieval system of claim 17, wherein thesuspension system of the autonomous transport vehicle is configured tomaintain the drive wheels of the drive section in substantial contactwith the transport surface.
 19. The automated storage and retrievalsystem of claim 15, wherein the suspension system of the autonomoustransport vehicle includes a pivot member mounted to one of the frameand the drive section and a pivot axle mounted to the other one of theframe and the drive section, where the pivot axle and pivot member areconfigured to engage each other to form a pivot coupling between theframe and the drive section.
 20. The automated storage and retrievalsystem of claim 15, wherein the payload justification system of theautonomous transport vehicle is configured for two degree of freedompayload positioning within the frame.